This document summarizes a study on the effect of process parameters on the strength of resistance spot welded aluminum alloy A5052 sheets with cover plates. The researchers welded 1mm thick aluminum alloy sheets using resistance spot welding with cold-rolled steel cover plates. They investigated the effect of welding current, time, and electrode force on nugget diameter, tensile-shear strength, and failure mode. Increasing welding current and time increased nugget diameter and strength, while increasing electrode force decreased nugget diameter and strength. Hardness was lowest in the nugget region compared to the base metal. Interfacial failure occurred for smaller nuggets and nugget pullout failure for larger nuggets
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Mechanical property assessment of austempered and conventionally hardened aisiIAEME Publication
The document summarizes a study that assessed the mechanical properties of AISI 4340 steel that underwent austempering heat treatment versus conventional hardening. Specimens were subjected to tensile, torsion, hardness, impact, and microstructure tests in the as-bought, austempered, and conventionally hardened conditions. Austempering improved tensile, torsional, and impact strength compared to conventional hardening, though it showed a slight decrease in hardness. Lower bainitic and martensitic microstructures were observed after austempering and conventional hardening, respectively.
The document discusses a research project analyzing the formability and wrinkling limits of various high strength steel sheets supplied by TATA Steel. Dr. R. Narayanasamy is the principal investigator, studying properties like tensile strength, forming limit diagrams, strain distribution, fractography, and texture. Tests were conducted on interstitial free steel, dual phase steel, and other varieties in thicknesses from 0.6mm to 2.0mm. Charts of chemical composition, microstructure, tensile properties, and forming limit diagrams are presented for each steel type.
IRJET- Fabrication and Characterization and Wear Analysis of Coated and Un...IRJET Journal
This document summarizes research on the fabrication and characterization of zinc aluminum alloy (ZA-27) metal matrix composites reinforced with silica nanoparticles. ZA-27 alloy was reinforced with 2%, 4%, and 6% by weight of both coated and uncoated silica nanoparticles via a stir casting method. The composites were then tested for mechanical properties including microhardness, tensile strength, flexural strength, and impact strength. Wear resistance was also evaluated using a pin-on-disc test. It was found that the addition of nanoparticles increased microhardness but decreased other mechanical properties slightly. Composites with coated nanoparticles exhibited improved wear resistance compared to uncoated nanoparticles.
This document describes the characterization and fabrication of an Al6063-Si metal matrix composite. Aluminum 6063 alloy was selected as the matrix material due to its light weight and strength. Silicon particles ranging from 5-8 wt% were used as reinforcement. The composites were produced using stir casting, where the matrix material was melted and silicon was added and stirred in. Hardness and tensile tests were performed according to standards. Results showed that hardness and tensile strength increased with higher silicon content, with the 8 wt% composite performing best. Microstructure analysis showed good dispersion of the reinforcement in the matrix.
Wear and corrosion studies on ferritic stainless steel (ss 409 m)eSAT Journals
Abstract The wear and corrosion behavior of SS 409M have been evaluated and compared with Mild steel ferritic stainless steel SS 430, and austenitic stainless steel SS 304. The SS 409M is a utility grade ferritic stainless steel, and has a very low Ni percentage less than 0.30%. Annealed SS 409M contains ferrite and low percentage of tempered martensite whereas normalized SS 409M has low ferrite and higher percentage of tempered martensite. The manufacturing cost for this steel is low as compared to other grades of stainless steel but it has high strength with excellent corrosion resistance, abrasion resistance and can be easily fabricated. Thus SS 409M has been found to be a suitable material for replacing mild steel in structural applications. SS 409M has also got good wear resistance and this can be considered as an alternate material for mild steel in the railway wagons, track armor, and chemical tanks. The dry wear test has been carried out using the pin on disc machine for all the specimens. The results show that 409M has higher wear resistance as compared to mild steel and SS 430. The corrosion test has been carried out using the potentiostat for SS 409M both in annealed and in the normalized condition and the results are compared with SS 430 and SS 304. SS 304 and SS 430 stainless steels show excellent corrosion resistance while SS 409M both in annealed and in normalized condition reveal higher corrosion resistance than mild steel. Results are discussed with published work on these steels. Keywords: SS 409M, SS 409M, SS 430, SS 304
To find effects of GMAW parameters on Mechanical Properties of Aluminum AlloysIJERA Editor
The present research aims to investigate the effects of Gas Metal Arc Welding (GMAW) on the mechanical
properties of different grades of aluminum alloys. GMAW is the most common method of joining aluminum
alloys used in various industrial processes. It replaces the Tungsten Inert Gas (TIG) method of providing equally
high quality of joints with a much higher performance. Aluminum alloys under consideration for this
experiment will be from 6XXX series, consisting of Silicon and Magnesium as main alloying elements. Weld
joints Will be produced with the help of a Gas Metal Arc Welding (GMAW) process. The Hardness, Tensile
strength, yield stresses and elongation will be the mechanical properties to be obtained. As aluminum alloys
show large micro structural changes after welding it is necessary to know about the effect of welding parameters
on the mechanical properties of weldements as too high welding current and too high welding speed will result
in high heat input and weakening of weld profile so a balance is need to be struck between welding parameters
and mechanical properties. Scattering Electron Microscopy (SEM) technique will be used to analyze micro
IRJET-Ballistic Performance of Bi-Layer Alumina/Aluminium and Honeycomb Sandw...IRJET Journal
This document summarizes numerical simulations of the ballistic performance of aluminum honeycomb sandwich structures with alumina ceramic face plates compared to a bi-layer alumina/aluminum armor. The simulations were conducted using HyperWorks Radioss finite element software. Validation of the model showed it could approximate the results for a bi-layer armor from a reference with 2.5% error. The simulations found that decreasing the honeycomb foil thickness and increasing the honeycomb thickness (while maintaining total thickness) resulted in lower residual velocities of the projectile, indicating better energy absorption. A honeycomb sandwich structure with 0.04mm foil thickness had the best performance overall compared to the bi-layer armor, absorbing more kinetic energy from the projectile
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Mechanical property assessment of austempered and conventionally hardened aisiIAEME Publication
The document summarizes a study that assessed the mechanical properties of AISI 4340 steel that underwent austempering heat treatment versus conventional hardening. Specimens were subjected to tensile, torsion, hardness, impact, and microstructure tests in the as-bought, austempered, and conventionally hardened conditions. Austempering improved tensile, torsional, and impact strength compared to conventional hardening, though it showed a slight decrease in hardness. Lower bainitic and martensitic microstructures were observed after austempering and conventional hardening, respectively.
The document discusses a research project analyzing the formability and wrinkling limits of various high strength steel sheets supplied by TATA Steel. Dr. R. Narayanasamy is the principal investigator, studying properties like tensile strength, forming limit diagrams, strain distribution, fractography, and texture. Tests were conducted on interstitial free steel, dual phase steel, and other varieties in thicknesses from 0.6mm to 2.0mm. Charts of chemical composition, microstructure, tensile properties, and forming limit diagrams are presented for each steel type.
IRJET- Fabrication and Characterization and Wear Analysis of Coated and Un...IRJET Journal
This document summarizes research on the fabrication and characterization of zinc aluminum alloy (ZA-27) metal matrix composites reinforced with silica nanoparticles. ZA-27 alloy was reinforced with 2%, 4%, and 6% by weight of both coated and uncoated silica nanoparticles via a stir casting method. The composites were then tested for mechanical properties including microhardness, tensile strength, flexural strength, and impact strength. Wear resistance was also evaluated using a pin-on-disc test. It was found that the addition of nanoparticles increased microhardness but decreased other mechanical properties slightly. Composites with coated nanoparticles exhibited improved wear resistance compared to uncoated nanoparticles.
This document describes the characterization and fabrication of an Al6063-Si metal matrix composite. Aluminum 6063 alloy was selected as the matrix material due to its light weight and strength. Silicon particles ranging from 5-8 wt% were used as reinforcement. The composites were produced using stir casting, where the matrix material was melted and silicon was added and stirred in. Hardness and tensile tests were performed according to standards. Results showed that hardness and tensile strength increased with higher silicon content, with the 8 wt% composite performing best. Microstructure analysis showed good dispersion of the reinforcement in the matrix.
Wear and corrosion studies on ferritic stainless steel (ss 409 m)eSAT Journals
Abstract The wear and corrosion behavior of SS 409M have been evaluated and compared with Mild steel ferritic stainless steel SS 430, and austenitic stainless steel SS 304. The SS 409M is a utility grade ferritic stainless steel, and has a very low Ni percentage less than 0.30%. Annealed SS 409M contains ferrite and low percentage of tempered martensite whereas normalized SS 409M has low ferrite and higher percentage of tempered martensite. The manufacturing cost for this steel is low as compared to other grades of stainless steel but it has high strength with excellent corrosion resistance, abrasion resistance and can be easily fabricated. Thus SS 409M has been found to be a suitable material for replacing mild steel in structural applications. SS 409M has also got good wear resistance and this can be considered as an alternate material for mild steel in the railway wagons, track armor, and chemical tanks. The dry wear test has been carried out using the pin on disc machine for all the specimens. The results show that 409M has higher wear resistance as compared to mild steel and SS 430. The corrosion test has been carried out using the potentiostat for SS 409M both in annealed and in the normalized condition and the results are compared with SS 430 and SS 304. SS 304 and SS 430 stainless steels show excellent corrosion resistance while SS 409M both in annealed and in normalized condition reveal higher corrosion resistance than mild steel. Results are discussed with published work on these steels. Keywords: SS 409M, SS 409M, SS 430, SS 304
To find effects of GMAW parameters on Mechanical Properties of Aluminum AlloysIJERA Editor
The present research aims to investigate the effects of Gas Metal Arc Welding (GMAW) on the mechanical
properties of different grades of aluminum alloys. GMAW is the most common method of joining aluminum
alloys used in various industrial processes. It replaces the Tungsten Inert Gas (TIG) method of providing equally
high quality of joints with a much higher performance. Aluminum alloys under consideration for this
experiment will be from 6XXX series, consisting of Silicon and Magnesium as main alloying elements. Weld
joints Will be produced with the help of a Gas Metal Arc Welding (GMAW) process. The Hardness, Tensile
strength, yield stresses and elongation will be the mechanical properties to be obtained. As aluminum alloys
show large micro structural changes after welding it is necessary to know about the effect of welding parameters
on the mechanical properties of weldements as too high welding current and too high welding speed will result
in high heat input and weakening of weld profile so a balance is need to be struck between welding parameters
and mechanical properties. Scattering Electron Microscopy (SEM) technique will be used to analyze micro
IRJET-Ballistic Performance of Bi-Layer Alumina/Aluminium and Honeycomb Sandw...IRJET Journal
This document summarizes numerical simulations of the ballistic performance of aluminum honeycomb sandwich structures with alumina ceramic face plates compared to a bi-layer alumina/aluminum armor. The simulations were conducted using HyperWorks Radioss finite element software. Validation of the model showed it could approximate the results for a bi-layer armor from a reference with 2.5% error. The simulations found that decreasing the honeycomb foil thickness and increasing the honeycomb thickness (while maintaining total thickness) resulted in lower residual velocities of the projectile, indicating better energy absorption. A honeycomb sandwich structure with 0.04mm foil thickness had the best performance overall compared to the bi-layer armor, absorbing more kinetic energy from the projectile
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
This document analyzes the fatigue behavior of two high-strength steels, HR590 and HR590DP. Low-cycle fatigue testing was conducted to characterize the mechanical properties of each steel and quantify their strain-life relationships. The precipitation strengthened HR590 showed more resistance to plastic deformation than the dual phase HR590DP. Future work is recommended to further study dislocation behavior, establish high-cycle fatigue properties, and test notched specimens and full components under dynamic loading.
This document summarizes a study on the effect of chromium content on the microstructure and wear resistance of Fe-Cr-C hard facing layers. Hard facing layers containing various amounts of chromium were deposited on mild steel using shielded metal arc welding. Testing found that microstructure consisted of primary (Cr, Fe)7C3 carbides and eutectic phases. Higher chromium content refined the carbides. Wear resistance testing found that higher chromium, carbon, and silicon content resulted in higher hardness and less wear. Electrode I, with higher amounts of these elements, exhibited less wear than Electrode II. In conclusion, chromium content significantly affects microstructure and wear resistance, with higher chromium improving hardness and wear performance of Fe
The document summarizes a study that investigated the effects of cutting speed, feed rate, and depth of cut on surface roughness and power consumption when turning 6063 aluminum alloy reinforced with 5% and 10% titanium carbide composites. 27 experimental runs were conducted using a full factorial design varying the machining parameters at three levels. Analysis of variance was used to determine the percentage contribution of each parameter on surface roughness and power consumption. The results showed that feed rate is the most significant parameter affecting surface roughness, while cutting speed has the greatest effect on power consumption. The conclusions provide insights on optimizing the machining parameters to minimize surface roughness and power usage during machining of these metal matrix composites.
Sheet Metal Welding Conference Detroit MichiganGajendra Tawade
This document summarizes research on developing robust spot welding processes for joining advanced high-strength steels used in automotive manufacturing. Spot welding tests were conducted on DP600 steel and HSLA 350 steel combinations. Different pulse types were used to widen the welding lobes and improve process flexibility. A novel two-pulse cycle removed zinc coating with the first pulse and controlled nugget growth with the second pulse at lower current, significantly increasing the welding lobe width. The research aims to enable increased use of advanced high-strength steels for building lighter, safer, and more fuel efficient vehicles.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Dr. R. Narayanasamy - Presentation on Formability of Deep Drawing Grade SteelsDr.Ramaswamy Narayanasamy
Step 1: The document summarizes a presentation given by Dr. Ramaswamy Narayanasamy on the formability of deep drawing grade steels.
Step 2: It provides details of the speaker's achievements and scientific contributions related to sheet metal forming and formability studies on various steel grades.
Step 3: The presentation describes the methodology used to construct forming limit diagrams (FLDs), including the different strain conditions tested, grid circle marking on sheet specimens, measurement of strain after deformation, and plotting of the FLD curves.
Investigation of Mechanical Properties of Rivet Joints For Grade-5 TitaniumSantanudeori2
This document discusses an investigation into the mechanical properties of rivet joints for grade 5 titanium. It begins with an introduction that describes the importance of riveting in aircraft manufacturing, noting it covers 95% of aircraft bodies. The document then describes the testing of solid shank and blind rivets on titanium grade 5 plates, including tensile tests, shear stress tests, torsion tests, and Charpy impact tests. The conclusion is that both rivet types were properly installed on the titanium and mechanical properties like tensile strength and shear stress were evaluated to optimize rivet joints for aircraft components made of grade 5 titanium.
This document summarizes a study on the effect of longitudinal weld pool oscillation (LWPO) on the tensile properties of mild steel welds. Mild steel plates were welded with varying frequencies (0-400 Hz) and amplitudes (0-30μm) of LWPO. Test specimens were tested and properties like yield strength, ultimate tensile strength, elongation and impact strength were determined. The results showed that properties like yield strength and ultimate tensile strength improved significantly with LWPO compared to stationary welds. The maximum 21.37% increase in yield strength and 20.87% increase in ultimate tensile strength occurred at 400Hz and 5μm oscillation. Microstructural analysis found that
This document discusses super plasticity, which is a deformation process that produces high elongations in metallic materials during tension testing. For super plasticity to occur, the material must have an ultra fine grain size and be deformed at a temperature greater than or equal to 0.4 times the absolute melting point. The document outlines various constitutive relationships that describe super plastic deformation and discusses factors that influence strain rate sensitivity. It also examines conditions necessary for super plastic forming and methods for producing ultrafine grain sizes in materials.
IRJET- Evolution of Tensile and Fracture Toughness Properties of Aluminum-707...IRJET Journal
This document summarizes an experimental study that investigated the tensile and fracture toughness properties of an aluminum-7075 alloy reinforced with zirconium silicate particulates. Specimens with various weight percentages (3%, 6%, 9%, 12%) of zirconium silicate reinforcement were fabricated using stir casting and tested according to ASTM standards. The results showed that the ultimate tensile strength and fracture toughness were improved with 9% zirconium silicate reinforcement but decreased at 12% reinforcement. The study aimed to determine the effect of zirconium silicate particulate reinforcement on the mechanical properties of aluminum-7075 alloy.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
Comparison of Effect of Heat Treatment Schedules and Shot Peening Parameters ...IRJET Journal
1) The document compares the effect of different heat treatment schedules and shot peening parameters on the abrasive wear behavior of medium carbon steel.
2) It investigates the wear resistance of as-received steel and steel subjected to annealing, intercritical annealing, and quenching and tempering. It also examines the effect of shot peening the steel samples using different shot sizes and pressures.
3) The results show that quenching and tempering produces the highest hardness and best wear resistance. Shot peening further reduces the wear rate, with an optimal shot size and pressure depending on the heat treatment used.
Study and Analysis of the Fatigue Behaviour of Friction Stir Butt Welded Dis...IRJET Journal
1) The study analyzed the tensile strength and fatigue behavior of friction stir butt welded dissimilar aluminum alloys AA6082 and AA5754.
2) Fatigue tests showed the dissimilar welds had lower tensile strength and fatigue strength than the base materials AA6082 and AA5754, but comparable strength to AA5754.
3) The fatigue performance of the AA6082 and AA5754 friction stir welded joints showed a shallower stress-life (S-N) curve with improved fatigue performance at lower stress ranges.
Optimisation of Welds with Manufacturing ConsiderationsSIMULIA
Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
Dr. R. Narayanasamy - Forming and fracture behavior of stainless steel 430 gr...Dr.Ramaswamy Narayanasamy
Presentation on Forming and fracture behavior of stainless steel 430 grade sheet metal by Dr. R. Narayanasamy, Retired Professor (HAG), Department of Production Engineering, NIT - Trichy
O documento descreve compromissos para a saúde no estado de Pernambuco e inclui: I) Complementar a rede hospitalar de alta e média complexidade com a construção de novos hospitais; II) Complementar a rede de média complexidade ambulatorial com a construção de Unidades de Pronto Atendimento Especializadas; III) Fortalecer o sistema de atendimento com programas como "O Doutor Chegou", "Medicamento em Casa" e "Saúde Conduz".
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
This document analyzes the fatigue behavior of two high-strength steels, HR590 and HR590DP. Low-cycle fatigue testing was conducted to characterize the mechanical properties of each steel and quantify their strain-life relationships. The precipitation strengthened HR590 showed more resistance to plastic deformation than the dual phase HR590DP. Future work is recommended to further study dislocation behavior, establish high-cycle fatigue properties, and test notched specimens and full components under dynamic loading.
This document summarizes a study on the effect of chromium content on the microstructure and wear resistance of Fe-Cr-C hard facing layers. Hard facing layers containing various amounts of chromium were deposited on mild steel using shielded metal arc welding. Testing found that microstructure consisted of primary (Cr, Fe)7C3 carbides and eutectic phases. Higher chromium content refined the carbides. Wear resistance testing found that higher chromium, carbon, and silicon content resulted in higher hardness and less wear. Electrode I, with higher amounts of these elements, exhibited less wear than Electrode II. In conclusion, chromium content significantly affects microstructure and wear resistance, with higher chromium improving hardness and wear performance of Fe
The document summarizes a study that investigated the effects of cutting speed, feed rate, and depth of cut on surface roughness and power consumption when turning 6063 aluminum alloy reinforced with 5% and 10% titanium carbide composites. 27 experimental runs were conducted using a full factorial design varying the machining parameters at three levels. Analysis of variance was used to determine the percentage contribution of each parameter on surface roughness and power consumption. The results showed that feed rate is the most significant parameter affecting surface roughness, while cutting speed has the greatest effect on power consumption. The conclusions provide insights on optimizing the machining parameters to minimize surface roughness and power usage during machining of these metal matrix composites.
Sheet Metal Welding Conference Detroit MichiganGajendra Tawade
This document summarizes research on developing robust spot welding processes for joining advanced high-strength steels used in automotive manufacturing. Spot welding tests were conducted on DP600 steel and HSLA 350 steel combinations. Different pulse types were used to widen the welding lobes and improve process flexibility. A novel two-pulse cycle removed zinc coating with the first pulse and controlled nugget growth with the second pulse at lower current, significantly increasing the welding lobe width. The research aims to enable increased use of advanced high-strength steels for building lighter, safer, and more fuel efficient vehicles.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Dr. R. Narayanasamy - Presentation on Formability of Deep Drawing Grade SteelsDr.Ramaswamy Narayanasamy
Step 1: The document summarizes a presentation given by Dr. Ramaswamy Narayanasamy on the formability of deep drawing grade steels.
Step 2: It provides details of the speaker's achievements and scientific contributions related to sheet metal forming and formability studies on various steel grades.
Step 3: The presentation describes the methodology used to construct forming limit diagrams (FLDs), including the different strain conditions tested, grid circle marking on sheet specimens, measurement of strain after deformation, and plotting of the FLD curves.
Investigation of Mechanical Properties of Rivet Joints For Grade-5 TitaniumSantanudeori2
This document discusses an investigation into the mechanical properties of rivet joints for grade 5 titanium. It begins with an introduction that describes the importance of riveting in aircraft manufacturing, noting it covers 95% of aircraft bodies. The document then describes the testing of solid shank and blind rivets on titanium grade 5 plates, including tensile tests, shear stress tests, torsion tests, and Charpy impact tests. The conclusion is that both rivet types were properly installed on the titanium and mechanical properties like tensile strength and shear stress were evaluated to optimize rivet joints for aircraft components made of grade 5 titanium.
This document summarizes a study on the effect of longitudinal weld pool oscillation (LWPO) on the tensile properties of mild steel welds. Mild steel plates were welded with varying frequencies (0-400 Hz) and amplitudes (0-30μm) of LWPO. Test specimens were tested and properties like yield strength, ultimate tensile strength, elongation and impact strength were determined. The results showed that properties like yield strength and ultimate tensile strength improved significantly with LWPO compared to stationary welds. The maximum 21.37% increase in yield strength and 20.87% increase in ultimate tensile strength occurred at 400Hz and 5μm oscillation. Microstructural analysis found that
This document discusses super plasticity, which is a deformation process that produces high elongations in metallic materials during tension testing. For super plasticity to occur, the material must have an ultra fine grain size and be deformed at a temperature greater than or equal to 0.4 times the absolute melting point. The document outlines various constitutive relationships that describe super plastic deformation and discusses factors that influence strain rate sensitivity. It also examines conditions necessary for super plastic forming and methods for producing ultrafine grain sizes in materials.
IRJET- Evolution of Tensile and Fracture Toughness Properties of Aluminum-707...IRJET Journal
This document summarizes an experimental study that investigated the tensile and fracture toughness properties of an aluminum-7075 alloy reinforced with zirconium silicate particulates. Specimens with various weight percentages (3%, 6%, 9%, 12%) of zirconium silicate reinforcement were fabricated using stir casting and tested according to ASTM standards. The results showed that the ultimate tensile strength and fracture toughness were improved with 9% zirconium silicate reinforcement but decreased at 12% reinforcement. The study aimed to determine the effect of zirconium silicate particulate reinforcement on the mechanical properties of aluminum-7075 alloy.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
Comparison of Effect of Heat Treatment Schedules and Shot Peening Parameters ...IRJET Journal
1) The document compares the effect of different heat treatment schedules and shot peening parameters on the abrasive wear behavior of medium carbon steel.
2) It investigates the wear resistance of as-received steel and steel subjected to annealing, intercritical annealing, and quenching and tempering. It also examines the effect of shot peening the steel samples using different shot sizes and pressures.
3) The results show that quenching and tempering produces the highest hardness and best wear resistance. Shot peening further reduces the wear rate, with an optimal shot size and pressure depending on the heat treatment used.
Study and Analysis of the Fatigue Behaviour of Friction Stir Butt Welded Dis...IRJET Journal
1) The study analyzed the tensile strength and fatigue behavior of friction stir butt welded dissimilar aluminum alloys AA6082 and AA5754.
2) Fatigue tests showed the dissimilar welds had lower tensile strength and fatigue strength than the base materials AA6082 and AA5754, but comparable strength to AA5754.
3) The fatigue performance of the AA6082 and AA5754 friction stir welded joints showed a shallower stress-life (S-N) curve with improved fatigue performance at lower stress ranges.
Optimisation of Welds with Manufacturing ConsiderationsSIMULIA
Fatigue is the main in-service failure mode for automotive chassis & suspension parts, especially weld fatigue. Over the years, Tata Steel Automotive Engineering (TSAE) has developed techniques for CAE durability assessment including the optimisation of seam-welded chassis/suspension structures. Seam weld optimisation at TSAE has previously been based on a constant weld length and constant gap between welds for each weld run. This method has two drawbacks; weld patterns generated are regular in nature, reducing the flexibility to position welds where they are most effective and• excessively short welds are often left at the end of a run of welds. The objective was to develop an improved optimisation technique using Isight that always produced a manufacturing feasible design and allowed more flexible and irregular positioning of welds. Manufacturing constraints considered were minimum weld length, minimum gap length and minimising the number of start/stop operations. To reduce the number of design variables, a new load-case-weighted optimisation scheme was developed using a single weighting factor for each load case. These factors were used to generate weld patterns by scaling the strain energy density in finite elements from an initial fully welded design. Weld elements were selected for retention/deletion by comparing a weighted sum across all load cases with a threshold value. During each optimisation, Isight varied the weighting factors as “design variables” to minimise overall weld length, while achieving stiffness and fatigue life targets. The process has been extended to function for laser weld designs where an intermittent weld pattern is generally the most effective.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
Dr. R. Narayanasamy - Forming and fracture behavior of stainless steel 430 gr...Dr.Ramaswamy Narayanasamy
Presentation on Forming and fracture behavior of stainless steel 430 grade sheet metal by Dr. R. Narayanasamy, Retired Professor (HAG), Department of Production Engineering, NIT - Trichy
O documento descreve compromissos para a saúde no estado de Pernambuco e inclui: I) Complementar a rede hospitalar de alta e média complexidade com a construção de novos hospitais; II) Complementar a rede de média complexidade ambulatorial com a construção de Unidades de Pronto Atendimento Especializadas; III) Fortalecer o sistema de atendimento com programas como "O Doutor Chegou", "Medicamento em Casa" e "Saúde Conduz".
Reuters: Pictures of the Year 2016 (Part 2)maditabalnco
This document contains 20 photos from news events around the world between January and November 2016. The photos show international events like the US presidential election, the conflict in Ukraine, the migrant crisis in Europe, the Rio Olympics, and more. They also depict human interest stories and natural phenomena from various countries.
The Six Highest Performing B2B Blog Post FormatsBarry Feldman
If your B2B blogging goals include earning social media shares and backlinks to boost your search rankings, this infographic lists the size best approaches.
1) The document discusses the opportunity for technology to improve organizational efficiency and transition economies into a "smart and clean world."
2) It argues that aggregate efficiency has stalled at around 22% for 30 years due to limitations of the Second Industrial Revolution, but that digitizing transport, energy, and communication through technologies like blockchain can help manage resources and increase efficiency.
3) Technologies like precision agriculture, cloud computing, robotics, and autonomous vehicles may allow for "dematerialization" and do more with fewer physical resources through effects like reduced waste and need for transportation/logistics infrastructure.
EXPERIMENTAL EVALUTION OF FRICTION STIR WELDED JOINTS OFsindhu rathod
This document summarizes an experimental evaluation of friction stir welded joints between dissimilar aluminum alloy plates. Key points:
- Friction stir welding was used to join AA6063 and AA6082 aluminum alloy plates using tools with and without TiAlN coating.
- Hardness tests and tensile tests were conducted on the welded joints. The welded joints produced using the coated tools showed higher ultimate tensile strength and hardness values compared to the uncoated tools.
- An optimal tool rotation speed of 1400 rpm and welding speed of 28 mm/min produced the highest weld strength. 2000 rpm and 28 mm/min produced the highest hardness values.
EFFECT OF TiO2 NANOPARTICLES ON FRICTION STIR WELDED JOINTS OF AA8011 ALUMINI...IRJET Journal
This document discusses a study investigating the effect of TiO2 nanoparticles on friction stir welded joints of AA8011 aluminum alloy. AA8011 aluminum alloy plates were friction stir welded with TiO2 nanoparticles added to the weld groove before welding. Various welding parameters were varied to evaluate their effect on the mechanical properties and microstructure of the welded joints. Tensile tests, impact tests, and microhardness tests were performed on the welded joints and results were compared to published data. The maximum tensile strength and impact value obtained were 52.98 MPa and 5.0 joules, respectively, at a rotational speed of 1400 RPM and welding speed of 25mm/min.
Comparative Study on the High-Stress Abrasive Wear Behaviour of Zinc and Copp...IRJET Journal
This document presents a comparative study on the abrasive wear behavior of zinc-based and copper-based alloys. Pin-on-disc tests were conducted on samples of the two alloys under varying loads and sliding distances. The zinc-based alloy exhibited higher wear rates and friction coefficients than the copper-based alloy. Microstructural analysis found the zinc alloy had a dendritic structure with intermetallic phases, while the copper alloy contained copper and intermetallic compounds. Temperature and friction increased with load and sliding time for both alloys, with the zinc alloy experiencing higher temperatures and friction. The copper alloy showed better wear resistance overall.
This document summarizes research on friction welding of 4140 steel. Friction welding was used to join cylindrical rods of 4140 steel, which is a chrome-moly steel commonly used in automotive applications. Various welding parameters were tested, including friction pressure, upset pressure, and rotational speed. Tensile tests showed that specimens welded with higher upset pressures and lower differences between upset and friction pressures had higher tensile strengths. Analysis of variance identified upset pressure and friction pressure as significant factors influencing weld strength. The research demonstrated friction welding 4140 steel is feasible and can achieve joint properties comparable to the base metal without requiring post-weld heat treatment.
4 ijcmes oct-2016-1-correlations on dissimilar materials by friction stir wel...IJCMESJOURNAL
Recently many reports on Friction Stir Welding (FSW) of various dissimilar systems such as Aluminium to Copper and Aluminium to Brass been reported. FSW of Aluminium, Copper and Brass has captured important attention from manufacturing industries, such as Shipbuilding, Automotive, Railway and Aircraft production. Brass materials are widely used as engineering materials in industry because of their high electrical and thermal conductivity, high strength, and high corrosion resistance. Copper and its alloys are widely used in industrial applications due to their excellent electrical & thermal conductivities, good strength, corrosion & fatigue resistance. The aim of present study was analogy of the microstructures and mechanical properties of friction stir welded joint of Aluminium to Copper and Aluminium to Brass plates in 4mm thickness.
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
This document evaluates the properties of dissimilar welds between a modified 12% chromium ferritic stainless steel and a carbon steel. Specimens of the two materials were welded using shielded metal arc welding and submerged arc welding with an austenitic stainless steel filler metal. The welds were tested for microstructure, hardness, toughness, mechanical properties, and corrosion resistance. Testing showed that the heat affected zone of the welds had Charpy impact values between 17-30 J, and cross-weld tensile specimens all broke in the base metals. The welds demonstrated acceptable properties for structural applications.
This document summarizes a study that investigated the effects of different quenching media (brine solution, water, diesel oil, and air) on the impact strength of single-vee butt welded mild steel joints. Samples of mild steel were welded using a coated electrode and then heat treated at temperatures from 2000°C to 6000°C before being quenched in the different media. Impact testing found that quenching in brine solution resulted in the lowest average impact strength, while quenching in air produced the highest average impact strength. Overall, the results indicated that air was the best quenching medium for welded mild steel, followed by diesel oil, water, and brine solution, when considering impact
Friction stir welding is used to join aluminum alloy AA6061 reinforced with 6% Al2O3 particles. Tests on welded specimens showed that ultimate tensile strength was highest at a tool rotation speed of 1100 rpm, while breaking stress and elongation were also highest. Hardness was lowest at this speed, resulting in the best overall joint efficiency. Microstructure, mechanical properties, and welding parameters were analyzed to characterize the friction stir welded aluminum metal matrix composite.
Experimental Investigation of Tensile Strength and Deflection Characteristics...IOSR Journals
This document presents an experimental investigation of the tensile strength and deflection characteristics of friction stir welded aluminum AA 6351 alloy joints. Tensile and deflection tests were carried out on friction stir welded specimens made with different tool rotational speeds. The results showed that tensile strength and breaking load increased with increasing rotational speed up to 950 rpm, but decreased at higher speeds. Deflections of friction stir welded specimens under different loads were similar to those of the base material specimens, indicating that friction stir welding does not negatively impact the deflection properties of the aluminum alloy. Overall, the joints welded at 950 rpm exhibited the highest tensile strength and breaking load compared to other welding conditions tested.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. Friction Stir Welding(FSW) process is an emerging solid state joining process in which
the material that is being welded does not melt and recast when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
The document experimentally investigates friction stir welding of aluminum AA6061 alloy joints. Tests were conducted to determine the surface roughness, Rockwell hardness, and tensile strength of friction stir welded AA6061 alloy joints at different tool rotational speeds and feed rates. The results found that surface roughness, hardness, and tensile strength values were optimized at a tool speed of 950 rpm and feed rate of 16 mm/min, with surface roughness and hardness initially increasing and then decreasing with tool speed, and tensile strength continuously increasing with tool speed up to the optimal values.
The document experimentally investigates friction stir welding of aluminum AA6061 alloy joints. Tests were conducted to determine the surface roughness, Rockwell hardness, and tensile strength of friction stir welded AA6061 alloy joints at different tool rotational speeds and feed rates. The results found that surface roughness, hardness, and tensile strength values were optimized at a tool speed of 950 rpm and feed rate of 16 mm/min, with surface roughness and hardness initially increasing and then decreasing with tool speed, and tensile strength continuously increasing with tool speed up to the optimal values.
This document summarizes an experimental investigation of welding distortion in austenitic stainless steel 316 using TIG welding. Taguchi methods were used to design experiments varying welding current, speed, and groove angle at three levels each. Welding was performed and distortion was measured. ANOVA was conducted to determine the significant parameters affecting distortion. Current was found to have the greatest effect, contributing 36% to distortion, while root gap contributed 43%. In conclusion, Taguchi methods allowed optimization of welding parameters to minimize distortion in stainless steel TIG welds.
This document summarizes an experimental investigation of welding distortion in austenitic stainless steel 316 using TIG welding. Taguchi methods were used to design experiments varying welding current, speed, and groove angle at three levels each. Welding was performed and distortion was measured. ANOVA was conducted to determine the significant parameters affecting distortion. Current was found to have the greatest effect on distortion, followed by groove angle, while speed had less influence. The goal of the study was to optimize welding parameters to minimize distortion using Taguchi methods.
IRJET - Evaluate the Residual Stress Formation of DP600 During RSWIRJET Journal
This study evaluated residual stress formation in DP600 dual phase steel sheets during resistance spot welding (RSW) at different pressures and currents. Samples of DP600 steel were resistance spot welded at pressures of 3.5, 4.5, and 5.5 bar and currents of 4, 6, and 8 kA. Microstructure, hardness, and residual stress of the welded samples were then examined. Results showed that hardness was highest in the weld region due to martensite formation from the high cooling rates of RSW. Hardness increased with higher clamping pressure and current. Residual stress measurements found compressive residual stresses in the specimens, with the highest stresses found in the 5 kA-6 bar samples.
This document summarizes a study that investigated the mechanical and metallurgical properties of friction stir welded AA1100 aluminum alloy joints. Different welding parameters were tested, including tool rotation speed (800-1400 rpm) and material positioning (advancing vs. retreating side). Microhardness, tensile, and fracture surface tests were used to evaluate the mechanical properties. Optical and SEM microscopy were used to analyze the microstructural evolution. The goal was to understand how processing parameters affect properties and defect development in similar AA1100 alloy joints.
Study of Pitting Corrosion Behavior of FSW weldments of AA6101- T6 Aluminium ...IJERA Editor
Friction Stir Welding (FSW) is a promising solid state joining process widely used generally for Al alloys,
especially in aerospace, marine and automobile applications. In present work, the microstructure and corrosion
behavior of friction stir welded AA6101 T6 Al alloy is studied. The friction stir welding was carried using
vertical milling machine with different tool rotational speeds and welding speeds. The microstructure at weld
nugget or stir zone (SN), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and base metal
were observed using optical microscopy. The corrosion tests of base alloy and welded joints were carried out in
3.5% NaCl solution at temperature of 30º C. Corrosion rate and emf were determined using cyclic polarization
measurement.
Approach to simultaneous improvement of strength, ductility
Fy2410811087
1. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
Effect Of Process Parameters On The Strength Of Aluminium
Alloy A5052 Sheets Joint Welded By Resistance Spot Welding
With Cover Plates
Chetan R. Patel*, Prof. Dhaval A. Patel**
*(M.E. MECHANICAL (CAD/CAM) Student, Sankalchand Patel College of Engineering, Visnagar, and
Gujarat, India
** (Department of Mechanical Engineering, Sankalchand Patel college of Engineering, Visnagar, Mehsana, and
Gujarat, India
ABSTRACT
Resistance spot welding (RSW) is the In automotive industries, weight reduction is strongly
most popular joining technique used by demanded for energy and natural resource savings.
automotive industries for the manufacture of Due to low density, its recovery potential and
automobile body structure. In automobile significant mechanical properties, aluminium alloys
industries, the weight saving effect of replacing have been adopted and are expected to be extensively
steel parts is an important factor in reducing fuel used in the future, to partially replace steel that is
consumption and increasing speed and natural primary construction material in automobile [2].
resources savings. In this study, A5052 aluminium The quality weld spot weld in aluminum
alloy sheet having 1 mm thickness were welded alloys is more sensitive to process variations than are
using the RSW with cover plates. The process similar welds is steels [9]. RSW of aluminium
parameters namely welding current, welding time requires three to four times more welding current
and electrode force considered for weld quality. than the resistance of an equivalent thickness of steel.
The welded joints were subjected to tensile shear Aluminium has young’s modulus is one third that of
and hardness tests to determine the influence of steel, aluminium is less resistance to surface
welding parameters effect on the quality of spot indentation from electrode contact. Thermal balance
welded joint. Also parameters effect on nugget in weld is difficult because surface oxidation changes
diameter and failure modes were studied. The the dynamic contact resistance characteristic at the
results showed that increase in welding current workpiece interface. In RSW of aluminium alloy the
and weld time tensile shear strength and nugget problems occurring are short electrode tip life and
diameter increased. While, increase in electrode surface oxidation [4].
force both nugget diameter and weld strength Though the effect of the process parameters on the
decreased. Hardness measurement results mechanical behavior of resistance spot welds on
indicated that nugget diameter gave the lowest carbon and stainless steels is well documented,
hardness value than base metal. The interfacial results from aluminium alloys continue to be scarce
failure mode occurs for nugget diameter up to [5-6]. In the previous study, magnesium alloy sheets
5.81 mm and above this value nugget pullout have been welded using the technique of RSW with
failure mode observed. The result reveals that the cover plates and favorable joint has been achieved
technique is feasible to weld aluminium alloy. under the welding condition of low welding current
[3]. In view of physical properties similarities
Keywords - Aluminium alloy, hardness, Nugget between aluminium alloy and magnesium alloy,
diameter, RSW, Tensile-shear load. aluminium alloy was also welded by using this
method in the present study.
In order to provide some foundational information for
I. INTRODUCTION
Resistance spot welding (RSW) is an improving mechanical properties of the aluminium
efficient joining process widely used for the alloy joint, the availability of this method for
aluminium alloy welding and the effect of welding
fabrication of sheet metal assemblies. RSW has
excellent techno-economic benefits such as low cost, parameters (welding current, weld time, electrode
high speed and suitability for automation which make force) on the characteristics of the joint were
it an attractive choice for auto-body assemblies such investigated.
as automobiles, truck cabins and rail vehicles. For
example, a modern auto-body assembly needs 7000 II. RSW WITH COVER PLATES
to 12,000 spots of welding according to the size of a RSW is a joining process based on the heat
car, so the spot welding is an important process in source obtained from Joule’s effect of resistance and
auto-body assembly [1]. electric current flow through the sheets held together
by the electrode force, in which the coalescence
occurs at the spot area in flying surfaces. Therefore in
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2. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
the process of RSW of aluminium alloy, enormously
high electric current required because of low heat
generation and high heat conduction of aluminium
alloy. In this case, the utilization of enormously high
welding current would reduce electrode tip life and
require adopting larger capacity RSW machine. In
order to enable the RSW of aluminium alloys sheets
under relatively low welding condition, we proposed
a technique of RSW with cover plate. Fig.1 and 2
shows the schematic diagram of this welding process,
in which a cover plate was placed on both the side of
aluminium alloy sheet. Here it is required that the
cover plate was a metal sheet with relatively low
electrical conductivity than aluminium alloy, so the Fig. 2 shape and size of specimen for welding
higher heat generated in the cover plates as to be Table 1 Dimensions of the work piece
conducted from the cover plate to aluminium alloy Thickness(t) Width (W) Length (L) Contact
sheet. Taking low cost and availability into account, mm mm mm overlap mm
we chose cold-rolled sheet SPCC as the cover plate.
1 40 100 30
The cover plate 30×40×1 mm in size was adopted.
The specimens were welded using a
III. EXPERIMENTAL MATERIALS AND stationary RSW machine as per welding condition in
PROCEDURE Table 3. Copper-chromium alloy electrodes with a tip
Aluminium alloy A5052 sheets of 1 mm diameter of 7 mm were used.
thickness were used in this study. Cold rolled steel Table 2 Chemical composition of material
plates were used for cover plates. Resistance spot Alloying Element Wt. %
welding lap joints with cover plates were done on
specimens of 100 mm × 40 mm × 1 mm in size Table Si 0.150
1. The nominal chemical composition of this alloy is
given in Table 2. Fig. 1 and Fig. 2 show the geometry Mn 0.012
and dimensions of the welded specimens. Sheet
surfaces were randomly abraded before resistance Cr 0.160
spot welding.
Ni 0.003
Cu 0.004
Al 97.000
Mg 2.400
Fe 0.240
Ti 0.010
All tests were performed at standard
laboratory conditions. Tensile-shear strength is an
important measure of welding quality of RSW.
Therefore, in this research tensile-shear strength has
been selected to describe the mechanical properties of
spot weld.
All the tensile-shear tests were carried out at
a crosshead speed of 2 mm/min on universal testing
machine UTES-40. Set-1, Set-2, Set-3 and Set-4 total
Fig. 1 Schematic diagram of resistance spot welding 22 spot welded specimens were tested on Universal
with cover plates Testing Machine for tensile shear load measurement.
Tensile loading was applied till final failure of the
weld specimens. Failure mode was determined from
the failed samples.
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3. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
Nugget diameter was measured after tensile shear test The hardness of the welds was measured on
fractured specimen achieved. Sometimes due to oval the parallel to the interface using a Vickers hardness
shape of the weld nugget geometry diameter tester. Set-5, set-6 and set-7 total 9 spot welded
measured in both the directions and average value of specimens were tested on Vickers hardness tester.
both was taken. Here set-1, set-2, set-3 and set-4 total Testing was performed with a 5 kgf indentation load
22 specimen’s nugget diameters were measured. All and with a hold time of 15 second. Hardness
specimens nugget diameter was measured by the measurements were carried out both the side from the
travelling microscope. weld nugget centre and average hardness values of
Table 3 Resistance spot welding condition for each both the sides of similar points was taken.
specimen series
IV. EXPERIMENTAL RESULTS AND
DISCUSSION
A. Tensile-shear load
The influence of the weld current on the
tensile-shear load is illustrated in Fig. 3 for set-1. A
significant increase in the tensile-shear load with
increasing weld current was observed, even for the
maximum current studied (9.8 kA). Increasing
welding current value T-S load increased with also
small expulsion of material was occurred. Welding
current values at 8.8 and 9.8 KA splashing of
material from weld nugget was observed. The reason
for this behavior is that the increase in current heat
input is increased as per the joule’s equation.
The effect of the weld time on the tensile shear load
is shown in Fig. 4 for set-2. A significant increase in
the T-S load was observed with increasing weld time.
With increasing welding time 5 cycles to 30 cycles T-
S load increasing 2.25 KN to 3.98 KN.
Fig. 3 Effect of welding current on Tensile-shear load
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4. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
with results observed by other authors in welds in
magnesium alloy [3].
Fig.7 shows the effect of welding time effect on the
nugget diameter of the joints welded under the
welding conditions of set-2. This demonstrates that
welding time has similar effect as studied in welding
current effect. The nugget diameter of the joint
increase with increasing the welding time increase
with increasing the welding time increase with
increasing the welding time.
Fig. 4 Effect of welding time on Tensile-shear load
Fig. 6 Effect of welding current on nugget diameter
Fig. 5 Effect of electrode force on Tensile-shear load
The effect of the electrode force on the T-S
load is shown in Fig. 5 for set-3. A minor decrease in
the T-S load was observed with increasing electrode
force. At 2050 electrode force maximum tensile shear
load value achieved after this it is decreased. With
increasing electrode force 1658 N to 3621 N T-S load
decreasing 2.56 KN to 2.20 KN. The reason behind is
increasing electrode force value increase contact
resistance due to that decreasing electric resistance
and also heat input.
B. Nugget diameter
The effect of the variation of weld current
on nugget diameter is shown in Fig. 6 for set-1. The
nugget diameter increases continuously with weld
current up to the maximum intensity that we have
tested. Initially 6.3 KA to 7.3 KA nugget diameters Fig.7 Effect of welding time on nugget diameter
increased rapidly after minor effect observed. Such
kind of behavior can be attributed to the increase in
heat input with increasing current and it agrees well
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5. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
Fig. 10 welding current effect on nugget diameter
Fig. 8 Effect of electrode force on nugget diameter Generally, welding current has effects on the tensile
Fig.8 illustrates the effect of electrode force on shear load and nugget diameter of joint. Fig.9 and
nugget diameter in the welds for set-3. Minimum Fig.10 shows the effect of welding current on the
electrode force value nugget diameter is 5.85 mm. tensile shear load and nugget diameter of the joints
With increasing electrode force value the nugget welded under the welding conditions of sets 1 and 4.
diameter reduced. The increase in the electrode force In the case of RSW with cover plates, the nugget
value can significantly improve the contact between diameter and tensile shear load of the joints increased
the faying surfaces. It also decreasing electrical with the increasing of the welding current. The
resistance and heat input so that this may be reason maximum tensile shear load of 3.04 KN and the
for the nugget diameter decrease with increasing the nugget of 6.05 mm in diameter was obtained at the
electrode force. welding current of 9.8 kA. While without cover
plates tensile shear load 0.46 KN and nugget
diameter 2.86 mm at the welding current of 9.8 KA.
C. Hardness
Fig. 9 welding current effect on tensile-shear load
Fig. 11 Hardness values of spot welded specimen at
different welding current condition
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6. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
joints and consequently reduces the hardness. After 3
mm away from the weld nugget centre hardness
value nearest same due to away from weld nugget no
more effect observed.
The effect of the electrode force on the
distribution of hardness in the welds is illustrated in
Fig. 13 in transverse direction of the spot welded
joints for set-7.The figure shows that an increase in
the electrode force the joints found as weaker that
leads to an increase in the hardness. Up to nugget
diameter and heat affected zone hardness values
slightly varies. This may be attributed to the
reduction in the amount of heat developed, due to the
reduction in the sheet resistance associated with the
increase in electrode force.
D. Failure mode
Fig. 12 Hardness values of spot welded specimen at Fig.15 shows the relationship between the weld
different weld time condition nugget diameter and the tensile shear load, from the
results of the tensile shear tests. Fig.14 shows two
different types of failure modes observed. An
approximately linear relationship was observed
between nugget diameter and tensile shear load.
The interfacial failure mode occurs for nugget
diameters up to 5.81mm while above this value
nugget pullout failure mode was observed. Currently,
in order to guarantee the reliability of the welds, the
welding parameters should be adjusted so that pullout
failure mode is obtained during testing. The result
revealed that the tensile shear load increased with the
increasing of the nugget diameter.
Fig. 13 Hardness values of a spot welded specimen at
different electrode force condition
Fig. 11 shows the effect of welding current on the
hardness of the spot welded joints for set-5,
illustrating that an increase in the welding current the
joints are stronger leads to a reduction in the hardness
value. The reason behind may be the increase in the
amount of heat developed. Increasing weld current
value from 6.8 to 9.8 in the nugget area hardness
values minor decreased. After 3 mm away from the
weld nugget centre hardness value almost constant.
The loss of alloying elements from the weld pool that
may result in a reduction in strength [7].
The effect of welding time on the hardness
of the spot welded joints for set-6, see Fig. 12. The
figure indicates that increasing the welding time
stronger joints achieved leads to a reduction in the
hardness. This reason behind is to the increase in the Fig. 14 RSW failure modes: (A) Pull out mode and
amount of heat developed. This heat anneals and (B) Interfacial mode
removes the residual stresses from the spot welded
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7. Chetan R. Patel , Prof. Dhaval A. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue4, July-august 2012, pp.1081-1087
[2] Hongxin Shi, Ranfeng Qiu, Jinhong Zhu,
Keke Zhang , Hua Yu, Gaojian Ding,
Effects of welding parameters on the
characteristics of magnesium alloy joint
welded by resistance spot welding with
cover plates, International journal of
Materials and Design 31 (2010) 4853–4857.
[3] Hongxin Shi, Ranfeng Qiu, Jinhong Zhu,
Keke Zhang, Hua Yu, Gaojian Ding.,
Effects of welding parameters on the
characteristics of magnesium alloy joint
welded by resistance spot welding with
cover plates, International journal of
Materials and Design 31 (2010) 4853–4857.
[4] Z. Li, C. Hao, J. Zhang, and H. Zhang,
Effects of Sheet Surface Conditions on
Electrode Life in Resistance Welding
Aluminum, Weld. J., 2007, 86(4), p 81s–
Fig. 15 Relationship between weld nugget size and 89s.
tensile shear load (for pull out failure and for [5] Murat Vural, Ahmet Akkus, On the
interfacial failure mode) resistance spot weldability of galvanized
interstitial free steel sheets with austenitic
V. CONCLUSION stainless steel sheets, Journal of Materials
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via a RSW method using cover plates. The joint with 6.
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was obtained under relatively low welding condition. mechanical properties in electrical resistance
With increasing welding current and time spot welding of sheets used in automotive
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hardness in the nugget and heat affected zones of the
welds.
The interfacial failure mode observed up to
nugget diameter 5.81 mm and above this value
pullout failure mode observed. Use of cover plates
for resistance spot welding of A5052 sheets is
feasible.
REFERENCES
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[1] Aslanlar S, Ogur A, Ozsarac U, Ilhan E.
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properties of automotive sheets in electrical
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